Method of manufacturing foam molded product, apparatus for manufacturing foam molded product, and foam molded product

ABSTRACT

The present invention is a method of manufacturing a foam molded product in which a foam molded product ( 1 A,  1 B) is formed by integrally adhering together a foam body ( 2 ) that is formed by the foaming of a foaming raw material, and an air-permeable component ( 3 ) using an apparatus for manufacturing a foam molded product ( 1 A,  1 B) that is provided with a cavity ( 23 ) between a plurality of mold components ( 21, 22, 31 ) that is defined by respective cavity surfaces ( 21   a,    22   a,    31   a ) of the mold components ( 21, 22, 31 ).

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a National Stage of International Application No.PCT/JP2011/066068, filed on July 14, 2011, which claims priority fromJapanese Patent Application No. 2010-159599, filed Jul. 14, 2010, thecontents of all of which are incorporated herein by reference in theirentirety.

TECHNICAL FIELD

The present invention relates to a method of manufacturing a foam moldedproduct formed by integrally adhering together a foam body formed by thefoaming of a foaming raw material, and an air-permeable component, to anapparatus for manufacturing a foam molded product, and to a foam moldedproduct. Priority is claimed on Japanese Patent Application No.2010-159599, filed Jul. 14, 2010, the contents of which are incorporatedherein by reference.

TECHNICAL BACKGROUND

A method such as that disclosed, for example, in Patent document 1 (seebelow) is known as a conventional method for manufacturing a foam moldedproduct. This method employs an apparatus for manufacturing a foammolded product that is provided with a cavity that is defined between aplurality of mold components by the respective cavity surfaces. Thiscavity is provided with a foaming start space to which the foam rawmaterial is supplied, and a foaming end space that is continuous withthe foaming start space and that the foam raw material reaches byperforming a foaming action within the foaming start space. This methodincludes a placement step in which, of the cavity surfaces, anair-permeable component is placed in the aperture cavity surface wheregas venting holes are formed, a supply step in which the foam rawmaterial is supplied to the foaming start space, and a foaming step inwhich the foam raw material is made to foam until it reaches the foamingend space so that a foam body is formed, and this foam body is thenintegrally adhered together with the air-permeable component. In thismanufacturing method, when the foaming step is being performed, foam gasand air and the like inside the cavity are expelled from the gas ventingholes via the air-permeable component while the foam raw material isperforming the foaming action inside the cavity, resulting in a foammolded product being formed.

DOCUMENTS OF THE PRIOR ART Patent Documents

-   [Patent document 1] Japanese Patent Application, First Publication    No. 2004-358910

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention

However, in the aforementioned conventional method of manufacturing afoam molded product, when the foaming step is being performed, there isa possibility that the foam gas and air and the like inside the foamingend space will not be expelled from the gas venting holes, and that thefoaming of the foam raw material will continue while pockets of foam gasand air and the like remain inside the foaming end space. Because ofthis, in a foam molded product that is formed by means of thismanufacturing method, it is easy for pockets of air to be formed in thefoam body by the foam gas and air remaining in the foaming end space,and this makes it difficult to form a foam molded product with a highdegree of precision.

The present invention was conceived in view of the above-describedcircumstances, and it is an object thereof to provide a method ofmanufacturing a foam molded product that makes it possible to form afoam molded product with a high degree of accuracy.

Means for Solving the Problem

In order to solve the above-described problems, the present inventionproposes the following measures. The method of manufacturing a foammolded product according to the present invention is a method ofmanufacturing a foam molded product in which a foam molded product isformed by integrally adhering together a foam body that is formed by thefoaming of a foaming raw material, and an air-permeable component usingan apparatus for manufacturing a foam molded product that is providedwith a cavity between a plurality of mold components that is defined byrespective cavity surfaces of the mold components. In the apparatus formanufacturing the foam molded product, the cavity is provided with afoaming start space to which the foam raw material is supplied, and afoaming end space that is continuous with the foaming start space andthat is filled by the foam raw material inside the foaming start spaceperforming a foaming action so as to spread as far as the foaming endspace. Of the cavity surfaces, peripheral edge portions of an aperturecavity surface in which gas venting holes open define the foaming endspace, and an inner side of peripheral edge portions of this aperturecavity surface define the foaming start space. The method ofmanufacturing a foam molded product includes: a placement step in whichthe air-permeable component is placed on the aperture cavity surface soas to cover the gas venting holes; a supply step in which the foam rawmaterial is supplied to the foaming start space; and a foaming step inwhich the foaming of the foaming raw material continues until it reachesthe foaming end space and the foaming end space has become tilled withthe foaming raw material so as to form the foam body, and the foam bodyand the air-permeable component are integrally adhered together. In theplacement step, the air-permeating component is placed on the aperturecavity surface such that it is connected to concave gas escape groovesthat are formed in peripheral edge portions of the aperture cavitysurface.

According to the present invention, when the placement step is beingperformed, the air-permeating component is placed on the aperture cavitysurface so as to be connected to the concave gas escape grooves. Becauseof this, when the foaming step is being performed, pockets of foam gasand air and the like that remain in the foaming end space can beexpelled from the gas venting holes via the concave gas escape groovesand the air-permeable component. Accordingly, the foam molded productcan be formed with a high degree of precision.

According to the present invention, when the placement step is beingperformed, the air-permeable component is placed on the aperture cavitysurface such that the outer peripheral edge of the air-permeablecomponent is positioned on the inner side of the peripheral end edge ofthe aperture cavity surface, which is continuous with the partingsurface. As a consequence of this, it is possible to restrain theair-permeable component from becoming placed between the mutuallyabutting parting surfaces. Furthermore, it is possible to limit anyobstruction to the foaming of the foaming component inside the foamingend space, which is caused by the air-permeable component. Accordingly,the interior of the foaming end space can be reliably filled by the foamof the foaming component, and it becomes possible to form a foam moldedproduct with a higher degree of accuracy.

The apparatus for manufacturing a foam molded product according to thepresent invention is an apparatus for manufacturing a foam moldedproduct that employs the above-described method of manufacturing a foammolded product, and in which the concave gas escape grooves are providedat a distance from the peripheral end edge of the aperture cavitysurface, which is continuous with the parting surface.

According to the present invention, the concave gas escape grooves areprovided at a distance from the peripheral end edge of the aperturecavity surface. As a consequence, when the foaming step is beingperformed, the foam raw material that is foaming inside the concave gasescape grooves is not able to intrude between the mutually abuttingparting surfaces from the concave gas escape grooves. Accordingly, it ispossible to discourage burrs being formed on the foam body, and the foammolded product can be reliably formed at a high level of accuracy.

Moreover, it is also possible for a sealing component to be providedbetween the mutually abutting parting surfaces so as to seal any gapbetween these parting surfaces.

In this case, the above-described functions and effects are clearlydemonstrated. Namely, because the sealing component is provided betweenthe mutually abutting parting surfaces, when the foaming step is beingperformed, it is difficult for the foam gas and air and the like thatare remaining in the foaming end space to be expelled to the outsidebetween the parting surfaces. However, because this foam gas and air andthe like are able to be expelled from the gas venting holes through theconcave gas escape grooves and the air-permeable component, it ispossible for the foam molded product to be formed with a higher degreeof accuracy even more reliably.

The foam molded product according to the present invention is a foammolded product that is formed by integrally adhering together a foambody, which is formed by the foaming of a foaming raw material, and anair-permeable component, and the foam molded product is manufactured byusing the above-described method of manufacturing a foam molded product.Convex bar portions are formed by the concave gas escape grooves on thesurface of the portion of the foam body that is formed by the foamingend space, and the air-permeable component is integrally adhered tothese convex bar portions.

According to the present invention, because the foam molded product ismanufactured by using the above-described method of manufacturing a foammolded product, it is difficult for air pockets to be formed in the foambody, and a high-precision foam molded product can be formed.

Effects of the Invention

According to the method of manufacturing a foam molded product and theapparatus for manufacturing a foam molded product of the presentinvention, it is possible to form a foam molded product with a highdegree of accuracy, and a high-precision foam molded product can beobtained as a result.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a seat that utilizes a seat padaccording to the present invention.

FIG. 2 is a perspective view showing the seat pad according to a firstembodiment of the present invention in an inverted state.

FIG. 3 is a view of a cross-section shown by the arrows A-A in FIG. 2.

FIG. 4 is a cross-sectional view of a metal mold that forms the seat padshown in FIG. 2.

FIG. 5 is a cross-sectional view of a metal mold that illustrates a seatpad manufacturing method that forms the seat pad shown in FIG. 2.

FIG. 6 is a plan view showing the seat pad according to a secondembodiment of the present invention in an inverted state.

FIG. 7 is a view of a cross-section shown by the arrows B-B in FIG. 6.

FIG. 8 is a cross-sectional view of a metal mold that forms the seat padshown in FIG. 6.

BEST EMBODIMENTS FOR IMPLEMENTING THE INVENTION

(First Embodiment)

Hereinafter, a seat pad according to a first embodiment of the presentinvention will be described with reference made to the drawings. As isshown in FIG. 1, seat pads 1A and 1B are used in a seat 1 of a vehicle,and are fixed to a seat frame (not shown) of this vehicle. Examples ofseat pads 1A and 1B such as these include a cushion pad (1A) that formsa sitting portion of the seat 1 in a vehicle, and a back pad (1B) thatforms a back rest portion of the seat 1 in a vehicle. The seat pad 1A ofthe present embodiment is used as the aforementioned cushion pad. Notethat, in the following description, when the seat pads 1A and 1B arefixed to the seat frame, a direction facing directly upwards is referredto as upward, a direction facing directly downwards is referred to asdownward, a direction facing towards the front of the vehicle isreferred to as forward, and a direction facing towards the rear of thevehicle is referred to as rearward.

As is shown in FIG. 2, the seat pad 1A is formed by integrally adheringtogether a foam body 2 that is formed by the foaming of a foam rawmaterial, and a reinforcing component (i.e., an air-permeable component)3. The foam body 2 is formed by the foaming of a foam raw material (forexample, a urethane raw material), and is formed, for example, frompolyurethane foam or the like. This foam body 2 is provided with a mainbody portion 4 on whose top surface a person is able to sit, and with aprotruding portion 5 that protrudes from a bottom surface of the mainbody portion 4.

The protruding portion 5 extends around substantially the entireperiphery of the outer peripheral edge of the main body portion 4. Aparting line portion 6 is formed running along the outer peripheral edgeon an end surface of the protruding portion 5. Convex bar portions 7that are formed by concave gas escape grooves 27 of a metal mold (i.e.,an apparatus for manufacturing a foam molded product) 20 (describedbelow) are provided protruding from a surface of the protruding portion5. The convex bar portions 7 are placed at a distance from the partingline portion 6. As is shown in FIG. 3, in a front portion 5 a of theprotruding portion 5 that is positioned on the front side, the convexbar portions 7 are provided in a curved shape so as to extend from aninside surface of the protruding portion 5 that faces towards a centerportion of the main body portion 4 as far as an end surface thereof.Furthermore, the plurality of convex bar portions 7 are placed at fixeddistances from each other on this front portion 5 a. The width andprotrusion height of the convex bar portions 7 are respectively set, forexample, to approximately 2 mm each, and the distance between adjacentconvex bar portions 7 is set to approximately 20 mm.

In this foam body 2, the seat frame of the vehicle is able to be fittedinside a concave portion that is defined on the bottom surface side ofthe main body portion 4 by the main body portion 4 and the protrudingportion 5. Furthermore, the bottom surface of the main body portion 4and the inside surface of the protruding portion 5 form a mountingsurface 8 on which the seat frame is mounted.

The reinforcing component 3 is an air-permeable, film-shaped componentand is formed, for example, from muslin cloth, coarse woolen felt, ornon-woven cloth or the like. The reinforcing component 3 is integrallyadhered to the mounting surface 8 of the foam body 2. In particular, inthe present embodiment, the reinforcing component 3 is integrallyadhered to the entire bottom surface of the main body portion 4, and isalso integrally adhered to the inside surface of the front portion 5 aof the protruding portion 5 and to the convex bar portions 7.

Next, as is shown in FIG. 4, a metal mold 20 that is used to manufacturethis seat pad 1A will be described. The metal mold 20 is provided with acavity 23 that is defined between a top mold 21 and a bottom mold 22(i.e., a plurality of mold components) by a cavity surface 21 a of thetop mold 21 and a cavity surface 22 a of the bottom mold 22. In thepresent embodiment, the cavity surface 22 a of the bottom mold 22 isformed as a depression in a center portion of the bottom mold 22. Thecavity surface 21 a of the top mold 21 is formed by making a centerportion of the top mold 21 protrude towards the bottom mold 22. Aparting surface 21 b that is continuous with a peripheral end edge 21 cof the cavity surface 21 a of the top mold 21 abuts against a partingsurface 22 b of the bottom mold 22. Between these parting surfaces 21 band 22 b, which are mutually abutting against each other, there isprovided a sealing component 28 that seals the gap between the partingsurfaces 21 b and 22 b.

The cavity 23 is provided with a foaming start space 24 to which thefoam raw material is supplied, and a foaming end space 25 that iscontinuous with the foaming start space 24, and that is filled when thefoam raw material performs a foaming action inside the foaming startspace 24 and spreads to the foaming end space 25. In the example shownin the drawing, the foaming start space 24 forms the main body portion 4of the foam body 2, while the foaming end space 25 forms the protrudingportion 5 of the foam body 2.

The foaming start space 24 is defined by an inner side 21 f of aperipheral edge portion 21 e of the cavity surface 21 a of the top mold21, and by an inner side of a peripheral edge portion of the cavitysurface 22 a of the bottom mold 22. Gas venting holes 26 that enable theinterior of the cavity 23 to communicate with the exterior thereofprovide openings to the foaming start space 24. A plurality of the gasventing holes 26 are formed in the cavity surface (i.e., an aperturecavity surface) 21 a of the top mold 21. The foaming end space 25extends around substantially the entire periphery of the outerperipheral edge of the foaming start space 24. This foaming end space 25is defined by the peripheral edge portion 21 e of the cavity surface 21a of the top mold 21 and by the peripheral edge portion of the cavitysurface 22 a of the bottom mold 22. The peripheral end edge 21 c of thecavity surface 21 a of the top mold 21 is positioned in this foaming endspace 25.

In the present embodiment, the concave gas escape grooves 27 are formedin the peripheral edge portion 21 e of the cavity surface 21 a of thetop mold 21. The concave gas escape grooves 27 are provided at adistance from the peripheral end edge 21 c of the cavity surface 21 a ofthe top mold 21. Moreover, the concave gas escape grooves 27 extend in adirection in which the foaming of the foam raw material advances fromthe foaming start space 24 towards the foaming end space 25 (i.e., inthe foaming direction). In the example shown in the drawing, a pluralityof concave gas escape grooves 27 are formed at intervals from each otherin the cavity surface 21 a of the top mold 21 such that they open ontothe portion of the foaming end space 25 where the front portion 5 a ofthe protruding portion 5 of the foam body 2 is formed. The width anddepth of the concave gas escape grooves 27 are respectively set, forexample, to approximately 2 mm each, and the distance between adjacentconcave gas escape grooves 27 is set to approximately 20 mm.

Next, a seat pad manufacturing method for forming the seat pad 1A byusing this metal mold 20 will be described. Firstly, as is shown in FIG.5, with the metal mold 20 in an open state, a placement step isperformed in which the reinforcing component 3 is placed on the cavitysurface 21 a of the top mold 21 so as to cover the gas venting holes 26.At this time, the reinforcing component 3 is placed on the cavitysurface 21 a of the top mold 21 so as to be connected to the concave gasescape grooves 27. When the reinforcing component 3 is being placed onthe cavity surface 21 a of the top mold 21, the outer peripheral edge ofthe reinforcing component 3 is positioned on the inner side of theperipheral end edge 21 c of the cavity surface 21 a of the top mold 21.

Next, a supply step is performed in which the foam raw material issupplied to the foaming start space 24. In this supply step, the foamraw material is injected, for example, into that portion of the innerside of the cavity surface 22 a of the bottom mold 22 where it isplanned to form the foaming start space 24, and the metal mold 20 isthen closed.

Next, a foaming step is performed in which the foam raw material is madeto foam inside the foaming start space 24. The foam raw material foamsin the foaming direction so that the interior of the cavity 23 graduallybecomes full of the foam raw material. At this time, the foam gas andair inside the foaming start space 24 are expelled from the gas ventingholes 26 via the reinforcing component 3, which is gas-permeable.Moreover, the foam gas and air inside the foaming end space 25 areexpelled from the gas venting holes 26 via the concave gas escapegrooves 27 and the reinforcing component 3.

The foam raw material then reaches the foaming end space 25 so that thefoaming end space 25 is filled with the foam raw material. The foamingof the foam raw material then abates, and the resinification (i.e., theresin reaction) of the foam raw material progresses so that the foambody 2 is formed inside the cavity 23, and the reinforcing component 3is integrally adhered to the foam body 2. As a result, the seat pad 1A,which is capable of maintaining a fixed shape, is formed, and thisfoaming step is ended. Thereafter, the metal mold 20 is opened, and ademolding step is performed in which the seat pad 1A is demolded fromthe metal mold 20. As a result, the seat pad 1A is obtained.

As has been described above, according to the method of manufacturing aseat pad according to the present embodiment, when the placement step isbeing performed, the reinforcing component 3 is placed on the cavitysurface 21 a of the top mold 21 so as to be connected to the concave gasescape grooves 27. Because of this, when the foaming step is beingperformed, any foam gas and air and the like remaining in the foamingend space 25 can be expelled from the gas venting holes 26 via theconcave gas escape grooves 27 and the reinforcing component 3. As aconsequence of this, the seat pad 1A can be formed with a high degree ofaccuracy.

Moreover, in the present embodiment, when the placement step is beingperformed, the reinforcing component 3 is placed on the cavity surface21 a of the top mold 21 such that the outer peripheral edge of thereinforcing component 3 is positioned on the inner side of theperipheral end edge 21 c of the cavity surface 21 a of the top mold 21.In this case, it is possible to restrain the reinforcing component 3from becoming placed between the mutually abutting parting surfaces 21 band 22 b.

Furthermore, when the placement step is being performed, by placing thereinforcing component 3 on the cavity surface 21 a of the top mold 21such that the outer peripheral edge of the reinforcing component 3 ispositioned on the inner side of the peripheral end edge 21 c of thecavity surface 21 a of the top mold 21, it is possible to limit anyobstruction caused by the reinforcing component 3 to the foaming of thefoaming component inside the foaming end space 25. Accordingly, theinterior of the foaming end space 25 can be reliably filled by thefoaming component as a result of the foaming component performing afoaming action, so that the seat pad 1A can be formed at a higher levelof accuracy.

Moreover, in the present embodiment, in the metal mold 20, the concavegas escape grooves 27 are provided at a distance from the peripheral endedge 21 c of the cavity surface 21 a of the top mold 21. Because ofthis, when the foaming step is being performed, the foam raw materialthat is foaming inside the concave gas escape grooves 27 is not able tointrude between the mutually abutting parting surfaces 21 b and 22 bfrom the concave gas escape grooves 27. Accordingly, it is possible todiscourage burrs being formed on the foam body 2, and the seat pad 1Acan be reliably formed at a high level of accuracy.

Moreover, in the present embodiment, the sealing component 28 isinterposed between the mutually abutting parting surfaces 21 b and 22 b.Because of this, the above-described functions and effects areeffectively demonstrated by the concave gas escape grooves 27 and thereinforcing component 3. Namely, because the sealing component 28 isprovided between the mutually abutting parting surfaces 21 b and 22 b,when the foaming step is being performed, it is difficult for the foamgas and air and the like that are remaining in the foaming end space 25to be expelled to the outside between the parting surfaces 21 b and 22b. However, this foam gas and air and the like are able to be expelledfrom the gas venting holes 26 through the concave gas escape grooves 27and the reinforcing component 3. Because of this, it is possible to forthe seat pad 1A to be formed at a high level of accuracy even morereliably.

Moreover, in the present embodiment, the seat pad 1A is manufactured byusing the above-described seat pad manufacturing method. Because ofthis, it is difficult for air pockets to be formed in the foam body 2,and a high-precision seat pad 1A can be formed.

(Second Embodiment)

Next, a seat pad according to a second embodiment of the presentinvention will be described. In this second embodiment, componentelements that are the same as those in the first embodiment are giventhe same descriptive symbols and no description thereof is given. Onlypoints of variance from the first embodiment are described.

As is shown in FIG. 1, a seat pad 1B of the present embodiment is usedas the aforementioned back pad, and is formed such that the back of anoccupant of the vehicle rests against a front surface of the main bodyportion 4 of the foam body 2. As is shown in FIG. 6 and FIG. 7, the foambody 2 is provided with a main body portion 4, a protruding portion 5,and a folded-back portion 9 that extends from the protruding portion 5towards the center portion of the main body portion 4. The folded-backportion 9 is provided on an inverted U-shaped upper portion 5 b of theprotruding portion 5 that, when seen in plan view, extends from bothside edges of the main body portion 4 as far as a top edge thereof and aparting line portion 6 is formed along a distal end surface of thisfolded-back portion 9.

A plurality of convex bar portions 7 a and 7 b are provided respectivelyon the folded-back portion 9 and on a lower portion 5 c that ispositioned on the bottom side of the protruding portion 5. As is shownin FIG. 7, of the convex bar portions 7 a and 7 b, the convex barportions 7 a, which are provided on the folded-back portion 9, are bentso as to extend from an inside surface of the folded-back portion 9 thatfaces towards the main body portion 4 as far as an end surface thereofFurthermore, the plurality of convex bar portions 7 a are arranged atfixed distances from each other on the folded-back portion 9. Moreover,of the convex bar portions 7 a and 7 b, the convex bar portions 7 b areprovided on the lower portion 5 c of the protruding portion 5. Theplurality of convex bar portions 7 b are arranged at fixed distancesfrom each other in a rectilinear configuration on an inside surface ofthe lower portion 5 c.

In this foam body 2, the mounting surface 8 is formed by a rear surfaceof the main body portion 4, and the inside surfaces of the protrudingportion 5 and the folded-back portion 9. In the present embodiment, thereinforcing component 3 is integrally adhered to the entire rear surfaceof the main body component 4, the inside surfaces of the protrudingportion 5 and the folded-back portion 9, and the convex bar portions 7 aand 7 b.

Next, as is shown in FIG. 8, a metal mold 30 that is used to manufacturethis seat pad 1B will be described. In the present embodiment, the metalmold 30 is provided with the top mold 21, the bottom mold 22, and acenter mold 31 that is attached to the top mold 21. The center mold 31is placed between central portions of the top mold 21 and the bottommold 22, and is attached to the central portion of the top mold 21.

A parting surface 31 b of the center mold 31 is abutted against aparting surface 21 d that is formed in a central portion of the top mold21, and the sealing component 28 is interposed between these partingsurfaces 31 b and 21 d. A plurality of the gas venting holes 26 areprovided in the center mold 31, and these open onto a cavity surface(i.e., an aperture cavity surface) 31 a of the center mold 31. Thefoaming start space 24 is defined by an inner side 31 f of a peripheraledge portion 31 e of the cavity surface 31 a of the center mold 31, andby the inner side of the peripheral edge portion of the cavity surface22 a of the bottom mold 22.

Out of two foaming end spaces 25 a and 25 b, a first foaming end space25 a that forms the upper portion 5 b of the protruding portion 5 isprovided with a first end portion 32 that forms the protruding portion5, and a second end portion 33 that forms the folded-back portion 9 thatis continuous with the first end portion 32. The second end portion 33is defined by the cavity surface 21 a of the top mold 21, and aperipheral edge portion 31 e of the cavity surface 31 a of the centermold 31. The peripheral end edge 31 c of the cavity surface 31 a of thecenter mold 31 is positioned on the second end portion 33. In addition,the concave gas escape grooves 27 are formed in the portion of theperipheral edge portion 31 e of the cavity surface 31 of the center mold31 that defines the second end portion 33.

On the other hand, the second foaming end space 25 b of the two foamingend spaces 25 a and 25 b that forms the lower portion 5 c of theprotruding portion 5 is defined by the cavity surface 21 a of the topmold 21, the peripheral edge portion of the cavity surface 22 a of thebottom mold 22, and the peripheral edge portion 31 e of the cavitysurface 31 a of the center mold 31. The peripheral end edge 31 c of thecavity surface 31 a of the center mold 31 is positioned in this secondend foam space 25 b. A plurality of the concave gas escape grooves 27are arranged at intervals from each other in the portion of theperipheral edge portion 31 e of the cavity surface 31 a of the centermold 31 that defines the second foaming end space 25 b.

As has been described above, according to the method of manufacturing aseat pad, the metal mold 30, and the seat pad 1B of the presentembodiment, the same type of functions and effects are obtained as fromthe first embodiment.

Note that the range of technology of the present invention is notlimited to the above-described embodiments, and various modificationsmay be made thereto insofar as they do not depart from the scope of thepresent invention. For example, in each of the above-describedembodiments, the sealing component 28 is interposed between the partingsurfaces 21 b, 22 b, 31 b, and 21 d of the metal molds 20 and 30.However, it is also possible for the sealing component 28 to be omitted.

Moreover, in each of the above-described embodiments, a plurality of thegas venting holes 26 and a plurality of the concave gas escape grooves27 are formed in the metal mold 20. However, it is also possible foronly one gas venting hole 26 and only one concave gas escape groove 27to be provided. Furthermore, in each of the above-described embodiments,the seat pads 1A and 1B are formed by integrally adhering theair-permeable reinforcing component 3 to the foam body 2. However,instead of the reinforcing component 3, it is also possible to employ adifferent component from the reinforcing component 3 that is alsoair-permeable. Furthermore, in each of the above-described embodiments,the seat pads 1A and 1B are employed as foam molded products. However,provided that the foam molded product is created by integrally adheringtogether a foam body and an air-permeable component, then it is notlimited to seat pads.

In addition to this, the component elements of the embodiments may alsobe replaced, where appropriate, with known component elements insofar asthey do not depart from the scope of the present invention, anddifferent combinations of the aforementioned variant examples may alsobe employed where appropriate.

INDUSTRIAL APPLICABILITY

According to the method of manufacturing a foam molded product and theapparatus for manufacturing a foam molded product of the presentinvention, it is possible to form a foam molded product with a highdegree of accuracy, and to thereby obtain a highly precise foam moldedproduct.

DESCRIPTION OF THE REFERENCE NUMERALS

-   1A, 1B . . . Seat pad (Foam molded product)-   2 . . . Foam body-   3 . . . Reinforcing component-   7, 7 a, 7 b . . . Convex bar portion-   20, 30 . . . Metal mold (Foam molded product manufacturing    apparatus)-   21 . . . Top mold (Mold component)-   21 a, 22 a, 31 a . . . Cavity surface-   21 b, 21 d, 22 b, 31 b . . . Parting surface-   21 c, 31 c . . . Cavity surface peripheral end edge-   21 e, 31 e . . . Cavity surface peripheral edge portion-   21 f, 31 f . . . Cavity surface peripheral edge portion inner side-   22 . . . Bottom mold (Mold component)-   23 . . . Cavity-   24 . . . Foaming start space-   25, 25 a, 25 b . . . Foaming end space-   26 . . . Gas venting hole-   27 . . . Concave gas escape groove-   28 . . . Sealing component-   31 . . . Center mold (Mold component)

The invention claimed is:
 1. A method of manufacturing a foam moldedproduct in which a foam molded product is formed by integrally adheringtogether a foam body that is formed by the foaming of a foam rawmaterial, and an air-permeable component using an apparatus formanufacturing a foam molded product that is provided with a cavitybetween a plurality of mold components that is defined by respectivecavity surfaces of the plurality of mold components, wherein the cavityis provided with a foaming start space to which the foam raw material issupplied, and a foaming end space that is continuous with the foamingstart space and that is filled by the foam raw material inside thefoaming start space performing a foaming action so as to spread as faras the foaming end space, and, of the cavity surfaces, peripheral edgeportions of an aperture cavity surface in which gas venting holes opendefine the foaming end space, and an inner side of peripheral edgeportions of this aperture cavity surface define the foaming start space,and concave gas escape grooves are provided at a distance from the gasventing holes, and extend in a direction in which the foaming of thefoam raw material advances from the foaming start space to the foamingend space, said gas escape grooves communicating with gas venting holes;and wherein the method of manufacturing a foam molded product includes:a placement step in which the air-permeable component is placed on theaperture cavity surface so as to cover the gas venting holes; a supplystep in which the foam raw material is supplied to the foaming startspace; and a foaming step in which the foaming of the foam raw materialcontinues until it reaches the foaming end space and the foaming endspace has become filled with the foam raw material so as to form thefoam body, and the foam body and the air-permeable component areintegrally adhered together, and wherein, in the placement step, theair-permeable component is placed on the aperture cavity surface suchthat it is connected to the concave gas escape grooves that are formedin peripheral edge portions of the, aperture cavity surface, andwherein, in the foaming step, foam gas is expelled from the gas ventingholes via the concave gas escape grooves and the air-permeablecomponent.